Modular enclosure system

ABSTRACT

A modular enclosure system and method for forming an enclosure are disclosed. The enclosure system includes a plurality of interchangeable edge rails constructed to engage a plurality of interchangeable corner connectors. The interchangeable edge rails include a flange constructed to engage and secure a plurality of panel sections to the enclosure thereby quickly and efficiently forming a desired volume enclosure.

BACKGROUND OF THE INVENTION

The present invention relates generally to enclosure assemblies and,more particularly, to a flexibly arrangeable modular enclosure system.

Enclosures come in a wide variety of styles and orientations and haveapplications that vary from storage cabinets to corrosion resistantelectrical boxes. These enclosures often come in variety of sizes aswell as a variety of materials depending, in part, on the intended useof the enclosure. Indoor, non-corrosive environment enclosures are oftenfabricated from generally lightweight plastic materials whereaselectrical cabinets in corrosive or industrial applications are oftenconstructed from a stainless steel material. Regardless of the intendeduse of the enclosure, these enclosures often come only in a variety ofstandard sizes. Requiring an enclosure having dimensions other than theprovided standard sizes either requires significant modification of astandard enclosure or ordering an enclosure that is then manufacturedwith the desired specifications. As such, requiring a custom madeenclosure having a size other than a commonly provided enclosurerequires either, significant time and labor to modify a commonenclosure, or a substantial increase in cost associated with a specialorder enclosure.

The intended use of an enclosure is an additional consideration ofenclosure construction. Enclosures generally referred to as electricalboxes generally provide knock-outs for openings through the enclosurehousing to allow wire access therein. Forming the knock-outs increasesthe production time required to form a single enclosure. The knock-outsare also often provided in a variety of standard configurations.Deviation from the standard knock-out orientation often requiressignificant in-field modification of the enclosure. As such, in-fieldmodification of the orientation of the knock-outs increases theinstallation time of the enclosure. Additionally, depending on thematerial the enclosure is constructed, any modification of the enclosuremay require special tooling and/or expertise to modify the enclosure.

Other enclosures, constructed from generally light weight plasticmaterials, lack a structural stability required for many applications.That is, these enclosures often require being supported on a floor andonce loaded or filled, must be unloaded or emptied in order to be moved.These enclosures often require a generally flat and/or smooth footingsurface in order to maintain the operability of doors that may beconnected thereto. Positioning the enclosure on a footing surface thatis even marginally non-planar and/or having a rough surface results inthe interconnected components of the enclosure being misaligned whichresults in improper, if not inoperable, association of the individualcomponents of the enclosure such as moveable shelves and enclosuredoors.

It would therefore be desirable to have an enclosure system having aplurality of components that are quickly and efficiently assembled, andeasily customized to a variety of user selected dimensions andapplications.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a modular enclosure system that solvesthe aforementioned problems. The enclosure system includes a pluralityof interchangeable corner rails connectable to a plurality ofinterchangeable corner connectors. The interchangeable corner rails andcorner connectors form a frame assembly constructed to receive aplurality of panel portions forming an enclosure about the frameassembly.

In accordance with one aspect of the present invention, an enclosuresystem is disclosed that includes a frame assembly. The frame assemblyincludes a plurality of edge rails, each edge rail being interchangeableand having a first end and a second end. The frame assembly alsoincludes a plurality of connectors, each connector being interchangeableand having a connector flange extending outwardly therefrom. Eachconnector is constructed to engage respective ends of a plurality of theedge rails. The enclosure system includes a plurality of side panelsconstructed to be attached to the frame assembly, each side panelconstructed to engage the connector flanges of a plurality of theconnectors.

In accordance with another aspect of the present invention, a cabinetsystem is disclosed that includes an edge component having a generallycurved portion and a pair of generally planar portions wherein ashoulder is formed between the generally curved portion and each of thegenerally planar portions. The cabinet system further includes a cornercomponent having a body and a plurality of generally curved sectionsextending therefrom. Each generally curved section is constructed to besnuggly received by the edge component between the shoulders formedthereon. Additionally, the cabinet system includes a plurality of sidepanels constructed to be received by the edge component on a sidegenerally opposite the corner component and oriented to enclose avolume.

In yet another aspect of the present invention, a method of forming anenclosure is disclosed that includes connecting a plurality ofinterchangeable corners with a plurality of interchangeable frame railsto form an enclosure frame having a plurality of generally uniform panelmounting flanges. The method also includes mounting an enclosure panelto each of the generally uniform panel mounting flanges therebyenclosing a volume.

According to another aspect of the present invention, a modularcontainer kit is disclosed that includes a plurality of cornerconnectors, a number of edge rails, and at least one sheet of generallyplanar material. The number of edge rails are of a predetermined lengthsuch that each of the edge rails are constructed to be severed to a userdesired length wherein each severed end is engageable with a cornerconnector to form a frame assembly. The at least one sheet of generallyplanar material is constructed to be severable into a plurality ofpanels to engage the frame assembly and form the modular container.

Various other features, objects and advantages of the present inventionwill be made apparent from the following detailed description and thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of an enclosure assembly according to oneembodiment of the present invention.

FIG. 2 is a perspective view of a portion of an edge rail of theenclosure assembly shown in FIG. 1.

FIG. 3 is an end view of the edge rail shown in FIG. 2.

FIG. 4 is a perspective view of one embodiment of a corner connector ofthe enclosure assembly shown in FIG. 1.

FIG. 5 is a perspective view of another embodiment of a corner connectorof the enclosure assembly of FIG. 1.

FIG. 6 is a perspective view of a door corner exploded from a door edgechannel of the enclosure assembly shown in FIG. 1.

FIG. 7 is a cross-sectional view of a corner, side panel, and doorassembly of the enclosure assembly shown in FIG. 1 taken along line 7-7.

FIG. 8 is a cross-sectional view of a corner assembly with a shelfbracket of the enclosure assembly shown in FIG. 1 taken alone line 8-8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows an enclosure assembly 10 according to the presentinvention. The enclosure assembly 10 includes a plurality of edge rails12 and a plurality of corner connectors 14 connected thereto. Edge rails12 and corner connectors 14 are constructed to be interchangeable witheach edge rail 12 and corner connector 14, respectively. Each cornerconnector 14 engages a plurality of the edge rails 12 such that theplurality of edge rails 12 and plurality of corner connectors 14cooperate to form a frame assembly 16. A plurality of side panels 18 areconnected to frame assembly 16 and enclose a cavity 17 therein.Enclosure assembly 10 includes a door assembly 20 that includes aplurality of door edge channels 22, a plurality of door cornerconnectors 24, a door panel 25, and a plurality of jam sections 26. Doorassembly 20 is pivotably or removeably connected to enclosure assembly10 by a hinge 27 or the like. A handle 28 provides a user of enclosureassembly 10 with selective access to cavity 17 contained therein.Optionally, door assembly 20 can include a window 30 to allow a user tovisually inspect the contents of cavity 17 of enclosure assembly 10without opening door assembly 20. It is equally understood that window30 could also be located at any of the plurality of side panels 18 ofenclosure assembly 10. Optionally, enclosure assembly 10 includes aplurality of adapters 30 constructed to quickly and efficiently connectto enclosure assembly 10 and allow connectivity with cavity 17 enclosedtherein. Passage adapters 30 can be constructed to interconnect with anyof a plurality of commonly used electrical, plumbing, gas, or othersystem lines or connectors. An optional pedestal assembly 32 includes aplurality of corner sections 34 interconnected by a plurality of railportions 36. Corner sections 34 and rail portions 36 areinterchangeable, respectively, and are constructed to be easily cut touser desired dimensions. Preferably, pedestal assembly 32 is constructedof a material similar to the material of enclosure assembly 10 and canbe quickly and efficiently connected thereto. Additionally, it isfurther understood that corner sections 34 can be constructed with a tab(not shown) internal or external thereto for securely mounting pedestalassembly 32 to a supporting surface such as a floor, cat walk, or thelike.

FIGS. 2 and 3 show edge rail 12 of enclosure assembly 10. As shown inFIG. 2, edge rail 12 includes a body portion 38 with a pair of edge railflanges 40 extending at edges 41 thereof. A step, or shoulder 42, isformed at the interface of each edge rail flange 40 and body 38 of eachedge rail 12. A channel 44 is formed in each edge rail flange 40 andextends a length therealong, the importance of which is discussedfurther below with respect to FIG. 7. As shown in FIG. 3, an interiorcontour 46 of edge rail 12 has a pair of shoulders 48 positionedproximate edge rail flanges 40. Edge rail flanges 40 extend from body 38in directions generally transverse to one another.

One embodiment of corner connector 14 is shown in FIG. 4. As shown inFIG. 4, corner connector 14 includes a body portion 50 with a pluralityof protrusions 52 extending therefrom. Each protrusion 52 is constructedto snugly engage an edge rail 12 of FIG. 1. Referring to FIGS. 3 and 4,an exterior contour 54 of each protrusion 52 of each corner connector 14is constructed to slidingly engage a respective interior contour 46 ofeach edge rail 12 between shoulders 48. A shoulder 56 of each protrusion52 of each corner connector 14 abuts, as shown in FIG. 2, an edge 58 ofeach edge rail 12. Referring again to FIG. 4, each corner connector 14includes a plurality of tabs 60 positioned between adjacent protrusions52 of corner connector 14. Tabs 60 are constructed to generally alignwith a respective edge rail flange 40 of a respective edge rail 12 thatis connected thereto. Such a construction forms what is commonlyreferred to as a butt joint between associated edge rails 12 and cornerconnectors 14. An alternate embodiment of corner connector 14 is shownin FIG. 5.

As shown in FIG. 5, corner connector 62 includes a body portion 64 witha plurality of protrusions 66 extending therefrom. Similar to eachcorner connector 14, an exterior contour 68 of each protrusion 66 ofcorner connector 62 is constructed to slidingly engage the interiorcontour 46 of edge rail 12, as shown in FIG. 3, between shoulders 48 ofa respective edge rail 12. Referring to FIGS. 3 and 5, body 38 of eachedge rail 12 is constructed to abut body portion 64 of a respectivecorner connector 62. A joint between edge rail flanges 40 of adjacentedge rails 12 forms one of what are commonly referred to as a half lapjoint or a miter joint between adjacent edge rail flanges 40. In thoseenclosure assemblies 10 where increased frame rigidity is desired, itmay be preferable to use corner connector 62 with the half lap joint ormiter joint between adjacent edge rails 12 as compared to the butt jointformed when using corner connector 14. Regardless of which cornerconnector is applied, the rigidity of enclosure assembly 10 is furtherincreased with the connection of side panels 18 thereto.

Similar to the engagement of corner connector and edge rail 12 of frameassembly 16, as shown in FIG. 6, door edge channels 22 and door cornerconnectors 24 of door assembly 20 are slidingly connected. Door cornerconnectors 24 include a body portion 70 with a pair of protrusions 72extending therefrom. Protrusion 72 is constructed to slidingly engage arecess 74 formed in door edge channel 22. A tab 76 is formed betweenprotrusions 72 of door corner connector 24 and is constructed togenerally align with a door edge channel flange 78 extending from dooredge channel 22. A groove 80 extends along a length of door edge channelflange 78 and is constructed to have door panel 25, as shown in FIG. 1,positioned thereacross.

FIG. 7 shows a cross-section of enclosure assembly 10 along line 7-7shown in FIG. 1. As shown in FIG. 7, protrusion 52, 66 snuggly engagesedge rail 12 between shoulders 48 and each side panel 18 traversesgroove 44 of edge rail flange 40 and abuts shoulder 42 of edge rail 12.Groove 44 is constructed to allow for the deposition of a bonding agent,such as glue, therein for fastening each side panel 18 to each edge rail12. Each edge rail 12 is further defined as an outside edge rail suchthat enclosure assembly 10 includes a plurality of inside edge rails 84constructed to be attached along a length of edge rail 12. Each insideedge rail 84 includes a pair of inside edge rail flanges 86 positionablealong edge rail flanges 40 of outside edge rail. Each inside edge railflange 86 of inside edge rail 84 includes a pair of grooves 88, 90.Groove 88 of inside edge rail flange 86 faces edge rail flange 40 ofoutside edge rail 12 and is configured to receive a bonding agenttherein thereby securing each inside edge rail 86 to a correspondingoutside edge rail 12. Groove 90 of inside edge rail flange 86 is alsoconstructed to receive a bonding agent therein such that an interiorpanel 92 of enclosure assembly 10 is securable thereacross.

A channel or chase 94 is maintained between inside edge rail 84 and acorresponding outside edge rail 12 and constructed to allow the passageof wiring therethrough. A cavity 96 is maintained between interiorpanels 92 and an adjacent side panel 18 of enclosure assembly 10.Optionally, an insulative material may be positioned or injected intocavity 96 thereby forming an insulated enclosure assembly. Jam sections26 of door assembly 20 include a channel 96 formed along a lengththereof. Channel 96 of each jam section 26 is constructed to snugglyreceive outside edge rail flange 40 and an associated inside edge railflange 86. Jam sections 26 also include a stop 98 extending therefrom.Stop 98 includes a gasket 100 positioned there at and constructed tosealingly engage door assembly 20 to enclosure assembly 10. Door edgechannel 22 engages gasket 100 and seals cavity 17 of enclosure assembly10 when door assembly 20 is oriented in a closed position. Grooves 80 ofdoor edge channel flange 78 of door edge channel 22 are constructed toreceive a bonding agent to secure door panel 25 and an interior doorpanel 102 about interconnected door edge channels 22. A cavity 106 isformed between door panels 25, 102 and is constructed to optionallyreceive an insulative material and/or a window 30, as shown in FIG. 1therebetween.

As shown in FIG. 8, a support bracket 108 is attached to inside edgerail 84. Support bracket 108 includes a pair of grooves 110 formedtherein and constructed to receive a bonding agent therein for securingsupport bracket 108 to enclosure assembly 10. Alternatively, amechanical fastener 112, such as a bolt, may be used to secure supportbracket 108 to inside edge rail 84 of enclosure assembly 10. As such,enclosure assembly 10 forms a sealed and insulated enclosure cavity thatdoes not require any mechanical fasteners in forming the enclosureassembly. Additionally, the enclosure assembly can be formed by apultrusion process having a plurality of interchangeable components.Alternatively, it is understood and within the scope of the claims thatthe plurality of interchangeable components of enclosure assembly 10could be formed by an extrusion process. Regardless of the processapplied to form the enclosure assembly, with a minimum of working, auser of the disclosed enclosure system can form an enclosure havingmultiple applications, sizes, and configurations with a minimum ofworkability of the individual components of the enclosure system.

In one embodiment of the present invention, an enclosure system includesa frame assembly. The frame assembly includes a plurality of edge rails,each edge rail being interchangeable and having a first end and a secondend. The frame assembly also includes a plurality of connectors, eachconnector being interchangeable and having a connector flange extendingoutwardly therefrom. Each connector is constructed to engage respectiveends of a plurality of the edge rails. The enclosure system includes aplurality of side panels constructed to be attached to the frameassembly, each side panel constructed to engage the connector flanges ofa plurality of the connectors.

An alternate embodiment of the present invention has a cabinet systemthat includes an edge component having a generally curved portion and apair of generally planar portions wherein a shoulder is formed betweenthe generally curved portion and each of the generally planar portions.The cabinet system also includes a corner component having a body and aplurality of generally curved sections extending therefrom. Eachgenerally curved section is constructed to be snuggly received by theedge component between the shoulders formed thereon. Additionally, thecabinet system includes a plurality of side panels constructed to bereceived by the edge component on a side generally opposite the cornercomponent and oriented to enclose a volume.

Another embodiment of the present invention includes a method of formingan enclosure that includes connecting a plurality of interchangeablecorners with a plurality of interchangeable frame rails to form anenclosure frame having a plurality of generally uniform panel mountingflanges and mounting an enclosure panel to each of the generally uniformpanel mounting flanges thereby enclosing a volume.

A further embodiment of the present invention includes a modularcontainer kit having a plurality of corner connectors, a number of edgerails, and at least one sheet of generally planar material. The numberof edge rails are of a predetermined length such that each of the edgerails are constructed to be severed to a user desired length whereineach severed end is engageable with a corner connector to form a frameassembly. The at least one sheet of generally planar material isconstructed to be severable into a plurality of panels to engage theframe assembly and form the modular container.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. An enclosure system comprising: a frame assembly comprising: aplurality of edge rails, each edge rail being interchangeable and havinga first end and a second end; a plurality of connectors, each connectorbeing interchangeable and having a connector flange extending outwardlytherefrom and constructed to engage respective ends of a plurality ofthe edge rails; and a plurality of side panels constructed to beattached to the frame assembly, each side panel constructed to engagethe connector flanges of a plurality of the connectors.
 2. The enclosuresystem of claim 1 wherein each of the edge rails further comprises arail flange extending therefrom and generally aligned with the connectorflange when connected thereto.
 3. The enclosure system of claim 2further comprising a groove formed in the rail flange, the groovetraversed by a side panel connected thereto.
 4. The enclosure system ofclaim 1 wherein the edge rails are further defined as an outside edgerail and wherein the system further comprises a plurality of insidecorner rails, each inside corner rail being interchangeable andconnectable along a length of a corresponding outside edge rail whilemaintaining a space therebetween.
 5. The enclosure system of claim 4wherein the space forms a wire chase that runs along a length of each ofthe inside corner rails.
 6. The enclosure system of claim 4 wherein theinside corner rail further comprises an inside corner rail flangeextending therefrom having a first groove formed therein, the firstgroove constructed to be traversed by the corresponding outside edgerail connected thereto.
 7. The enclosure system of claim 6 furthercomprising a second groove formed in the inside corner rail flange on aside of the inside corner rail flange generally opposite the firstgroove and constructed to be traversed by a cavity panel when the cavitypanel is connected thereto.
 8. The enclosure system of claim 6 furthercomprising an intermediate panel positioned between a side paneladjacent to a cavity panel.
 9. The enclosure system of claim 1 furthercomprising a door assembly having a plurality of jam sections, each jamsection engageable with at least one of a corresponding edge rail, anedge of a side panel, and an edge of a cavity panel.
 10. The enclosuresystem of claim 9 wherein the door assembly further comprises aplurality of door edge channels interconnected by a plurality of doorcorner connector.
 11. The enclosure system of claim 10 wherein the doorcorner connector further comprises a first tab engageable with a recessformed in one of the plurality of door edge channels and a second tabengageable with a recess formed in another of the plurality of door edgechannels.
 12. The enclosure system of claim 10 wherein the door assemblyfurther comprises a door panel fixedly connected to the plurality ofdoor edge channels, the door edge channel pivotably connected to atleast one of the jam sections.
 13. The enclosure system of claim 12wherein the door assembly further comprises another door panel connectedto the plurality of door edge channels and generally parallel to thedoor panel.
 14. The enclosure system of claim 1 further comprising awindow fixedly connected to at least one of the plurality of sidepanels.
 15. The enclosure system of claim 1 further comprising apedestal assembly having a plurality of side sections and a plurality ofinterchangeable corner connectors, the pedestal assembly constructed tobe attached to at least one of a plurality of the edge rails of theframe assembly and a side panel.
 16. The enclosure system of claim 1further comprising an adapter constructed to be connected to a sidepanel about a corresponding opening formed therethrough.
 17. Theenclosure system of claim 1 wherein at least one of the edge rails,connectors, and side panels are formed by a pultrusion-type process. 18.A cabinet system comprising: an edge component having a generally curvedportion and a pair of generally planar portions wherein a shoulder isformed between the generally curved portion and each of the generallyplanar portions; a corner component having a body and a plurality ofgenerally curved sections extending therefrom, each generally curvedsection constructed to be snuggly received by the edge component betweenthe shoulders formed thereon; and a plurality of side panels constructedto be received by the edge component on a side generally opposite thecorner component and oriented to enclose a volume.
 19. The cabinetsystem of claim 18 wherein the corner component further comprises aflange extending from the body between a pair of adjacent generallycurved portions, the flange constructed to be flush with at least one ofthe generally planar portions of the edge component when the cornercomponent is connected thereto.
 20. The cabinet system of claim 18wherein the plurality of generally curved sections of the cornercomponent are generally perpendicular to each other.
 21. The cabinetsystem of claim 18 wherein the corner component further comprises ashoulder formed between the body and each of the generally curvedportions, the shoulder constructed to abut an end of a correspondingedge component connected thereto.
 22. The cabinet system of claim 18wherein the edge component is further defined as an outside edgecomponent and the system further comprises an inside edge componenthaving a generally curved middle portion and a pair of generally planarend portions wherein each generally planar end portion is constructed toengage a corresponding generally planar portion of the outside edgecomponent.
 23. The cabinet system of claim 22 further comprising a chaseformed between the generally curved middle portion of the inside edgecomponent and the generally curved portion of a corresponding outsideedge component.
 24. The cabinet system of claim 22 further comprising aninterior panel attached to a corresponding end portion of the insideedge component and extending therebeyond on a side of the correspondingend portion generally opposite the generally planar portion of theoutside edge component.
 25. The cabinet system of claim 18 wherein atleast one of the edge component, the corner component, and at least oneof the plurality of side panels are formed by a protrusion-type process.26. A method of forming an enclosure comprising: connecting a pluralityof interchangeable corners with a plurality of interchangeable framerails to form an enclosure frame having a plurality of generally uniformpanel mounting flanges; and mounting an enclosure panel to each of thegenerally uniform panel mounting flanges thereby enclosing a volume. 27.The method of claim 26 wherein connecting each of the plurality ofinterchangeable corners with each of the plurality of interchangeableframe rails further comprises inserting a protrusion of a respectiveinterchangeable corner into a recess formed in an end of a correspondinginterchangeable rail connected thereto.
 28. The method of claim 26further comprising cutting each of the interchangeable frame rails to auser desired length.
 29. The method of claim 26 further comprisinggluing the enclosure panel to a respective generally uniform panelmounting flange.
 30. The method of claim 26 further comprising attachinga door to a respective enclosure panel to provide access to the volumeof the enclosure.
 31. The method of claim 30 further comprising forminga seal between the door and the respective enclosure panel when the dooris in a closed position.
 32. The method of claim 26 further comprisingattaching a bracket to at least one of the interchangeable frame railsinside the volume.
 33. The method of claim 26 further comprisingattaching an inside rail along a corresponding interchangeable framerail inside the volume and maintaining a passage therebetween.
 34. Themethod of claim 26 further comprising mounting another panel along alength of at least one of the interchangeable frame rails and generallyparallel to a corresponding enclosure panel and maintaining anothervolume therebetween.
 35. The method of claim 34 further comprisinginserting an insulator into the another volume prior to mounting theanother panel.
 36. The method of claim 26 further comprising attachingat least one adapter to an enclosure panel to allow communicationthrough the enclosure with the volume.
 37. A modular container kitcomprising: a plurality of corner connectors; a number of edge rails ofa predetermined length, each of which are constructed to be severed to auser desired length, wherein each severed end is engageable with acorner connector to form a frame assembly; and at least one sheet ofgenerally planar material that is constructed to be severable into aplurality of panels to engage the frame assembly and form the modularcontainer.
 38. The kit of claim 37 further comprising a door assemblyhaving a plurality of door corner connectors and a number of door edgerails of a predetermined length constructed to be cut to a user desiredlength, wherein each cut end is engageable with a door corner connectorto form a door frame assembly.
 39. The kit of claim 38 furthercomprising a number of door jam sections of a predetermined lengthconstructed to be cut to a user desired length and engageable with theframe assembly and constructed to receive the door frame assembly.